The waste generated by most manufacturing companies only adds to environmental degradation. But now, a company called Advance Nonwoven offers solutions to turn such waste into recycled products that often open up a new revenue channel, reports Ganesh Kalidas
Nonwoven fabrics, known as engineered fabrics, are created using scientific principles along with high-speed and low-cost processes. Using the machines created by Advance Nonwoven, customers can create products of their own choice using long as well as short fibers. The company’s patented Carding Airlaid Fusion Technology (CAFT) was developed with a view that it would provide for creating sustainable and renewable products from the waste of manufacturing units. The technology came about after it was introduced to the company by a woman who had worked upon the idea. It was something unique, never attempted before. And with the increase in environmental concerns, Advance Nonwovens realised this as an opportunity to help companies across the world reduce the amount of waste produced by reusing it.
The idea
The idea behind CAFT arose in 2006 with the objective of creating new commercial opportunities for sustainable and renewable products made from natural fibres, waste or recycled material, where Advance Nonwovens would supply the manufacturing equipment. The mission was and still is to develop and engineer a technology that can up-cycle or recycle what has previously been considered low-value, non-usable fibers and waste into high-value products and materials. This solution provides sustainable alternatives to a wide range of offerings such as insulation for buildings and machines, acoustic mats, furniture upholstery, growth mats for agriculture, food packaging and hard composition materials.
The process
To bring this miracle into reality it took an investment of Euro 5-6 million and nine years of effort and dedication. Another very special feature about this company is that it creates products which are 100% suitable to their customers. Moreover, the team at Advance Nonwovens is also open to ideas shared by the customers since they are comfortable working with all kinds of fibers.
Elaborates Flemming Werk, Director, Advance Nonwoven: “There are companies with manufacturing units which generate a lot of waste. Some companies are aware of the environmental hazards of such waste and attempt to convert it into a new product. We provide full assistance to such companies.”
“We help them convert the waste to a nonwoven mat which is later used for the purpose of creating something new,” he adds. The company has finally been able to achieve the feat of presenting a full nonwoven production line and is currently working on three factories worldwide to produce recycled goods. It has already collaborated with some companies, one of them being a Danish enterprise which has a very high rating in terms of corporate social responsibility. “It wanted to create a solid textile board from the nonwoven mat and sell it. With assistance from Advance Nonwoven, the company was successful in creating a good quality product,” informs Werk.
Customised solutions
Such recycled products are as good as new products since they last as long as the ones that are made from new natural fibers. This is because of the technology used. The CAFT excels in its ability to handle very short and long fibers, forming a uniform mat while using less bico fibers and more air when compared to competing technologies. Highlighting the advantages of working with Advance Nonwoven, Werk says: “What makes us popular among our customers is that we adjust according to the requirements of each one of them and provide them with a unique, durable and appealing product which is beneficial for the company since no extra resources are used.”
The company till now was under wraps and building itself up to show its worthiness. Its first big public announcement was at ITMA, Barcelona in 2019 where the technology was received with immense appreciation. The company has emerged as one-of-a-kind since it not only provides the technology but is also instrumental in supporting its clients with installation as well as product manufacturing. “We have had a huge response at ITMA, including inquiries from two Indian companies. What makes us exclusive is that our technology is supporting sustainable development across the world. For example, we have set up a factory in Africa to be able to offer jobs and affordable housing in an attempt to alleviate poverty,” Werk states.